Vehicle lamp

Abstract

To provide a vehicular lighting fixture capable of restraining influence of heat on a light distribution pattern.SOLUTION: A holder (80) including a pedestal portion (85) supporting the beam shaper (50) and a boss (90) extending from the pedestal portion (85) toward the beam shaper (50) and inserted into an 50h1 of the through hole, the holder (80) being located on a side opposite to the pedestal portion (85) with respect to the beam shaper (50), 50h1, washers 91 inserted into the bosses 90 and a fixing part 95 to which a part 50h1 separated from the through hole 50a in the beam shaper 50 is fixed are provided, and a part on the opposite side of the beam shaper 50 side from the washers 91 in the bosses 90 is thermally caulked.SELECTED DRAWING: Figure 10

Description

[Technical Field]

[0001] The present invention relates to a vehicle lamp. [Background technology]

[0002] BACKGROUND ART Vehicle lamps that include a reflecting member that reflects light emitted from a light source are known, and Patent Document 1 listed below discloses such a vehicle lamp.

[0003] In the vehicle lamp disclosed in Patent Document 1 below, a portion of the light emitted from the light source is irradiated onto the upper surface of the beam shaper, forming a cutoff line in the light distribution pattern, which becomes a low beam light distribution pattern. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] European Patent Application Publication No. 2982902 Summary of the Invention [Problem to be solved by the invention]

[0005] Although Patent Document 1 does not describe a method for fixing a beam shaper, there is a demand for attaching a reflective member, such as a beam shaper or reflector, that reflects light from a light source to a base of a vehicle lamp by heat crimping, in order to reduce costs, etc. In this case, the reflective member is attached by inserting a boss extending from the base into a through-hole in the reflective member and then heat crimping the boss. However, when the boss is heat crimped, the resin that makes up the boss may melt and enter the through-hole in the reflective member, fixing the reflective member to the base. When the reflective member is fixed to the base, the reflective member may bend due to thermal expansion caused by light from the light source, which may affect the light distribution pattern.

[0006] SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a vehicle headlamp that can suppress the influence of heat on the light distribution pattern. [Means for solving the problem]

[0007] In order to achieve the above object, the vehicle lamp of the present invention comprises a light source unit, a reflective member that reflects light from the light source unit and has a through hole formed therein, a support unit that supports the reflective member, and a base having a boss that extends from the support unit toward the reflective member and is inserted into the through hole, a washer that is located on the opposite side of the reflective member from the support unit and is inserted into the boss, and a fixing unit to which a portion of the reflective member that is spaced apart from the through hole is fixed, and is characterized in that the portion of the boss that is opposite the reflective member from the washer is heat-crimped.

[0008] With this configuration, the resin at the portion where the boss is heat-sealed can be blocked by the washer, compared to when the washer is not present. This can prevent the resin in the through-hole from adhering to the reflective member, making it easier for the position of the through-hole to move relative to the boss. Therefore, when the reflective member thermally expands due to light from the light source, the position of the through-hole can shift relative to the boss, preventing the reflective member from bending and reducing the thermal impact on the light distribution pattern.

[0009] It is preferable that at least a portion of the inner periphery of the washer overlaps the through hole.

[0010] With this configuration, compared to when the inner circumference of the washer does not overlap the through hole, the resin in the area where the boss is heat-sealed can be more easily blocked by the washer, and adhesion between the resin and the reflective member within the through hole can be further suppressed.

[0011] The washer is preferably made of resin.

[0012] The resin is preferably a fluororesin.

[0013] This configuration can reduce the coefficient of friction between the washer and the reflective member, which can facilitate misalignment when the reflective member thermally expands due to light from the light source, thereby further preventing the reflective member from bending.

[0014] The glass transition temperature of the resin constituting the boss is preferably lower than the glass transition temperature of the resin constituting the washer.

[0015] With this configuration, even if the heat-caulked portion of the boss melts, the washer can be made less likely to melt.

[0016] The washer is preferably fused to the boss.

[0017] With this configuration, rattle of the washer is less likely to occur compared to when the washer is not fused to the boss, and the generation of abnormal noise can be suppressed.

[0018] The through hole is preferably an elongated hole whose diameter in a direction from the part fixed to the fixing portion toward the through hole is longer than its diameter in a direction perpendicular to that direction.

[0019] With this configuration, compared to when the through hole is a round hole, positional deviation in a direction perpendicular to the direction from the part of the reflective member fixed to the fixing part toward the boss is suppressed, while the reflective member may shift when thermally expanding due to light from the light source part, preventing the reflective member from bending and suppressing the thermal effect on the light distribution pattern.

[0020] The reflective member includes a reflective portion that reflects light from the light source portion so that a low beam cutoff line is formed between the portion fixed by the fixing portion and the through hole, and a pair of connecting portions that connect the portion side and the through hole side of the reflective portion, respectively, and a slit may be formed in at least one of the pair of connecting portions.

[0021] With this configuration, when the reflecting member thermally expands due to light from the light source, the slits deform, thereby absorbing the deformation caused by the expansion, and bending of the reflecting member can be further suppressed. [Effects of the Invention]

[0022] As described above, according to the present invention, it is possible to provide a vehicle headlamp that can suppress the influence of heat on a light distribution pattern. [Brief explanation of the drawings]

[0023] [Figure 1] 1 is a side view showing a vehicle lamp according to an embodiment of the present invention; [Figure 2] FIG. 2 is an exploded perspective view showing the lamp unit. [Figure 3] FIG. [Figure 4] 4 is a cross-sectional view of the lamp unit taken along line IV-IV in FIG. 3. [Figure 5] 4 is a cross-sectional view of the lamp unit taken along line VV in FIG. 3. [Figure 6] FIG. 2 is a perspective view showing a shade and a reinforcing member. [Figure 7] FIG. [Figure 8] FIG. 10 is a front view showing a state in which the reinforcing member is superimposed on the shade. [Figure 9] FIG. 10 is a cross-sectional view showing a state in which a boss is inserted into the through-hole on the left side. [Figure 10] FIG. 10 is a cross-sectional view showing a state in which a boss is inserted into the through-hole on the right side. [Figure 11] FIG. 10 is an explanatory diagram showing the positional relationship between a washer and a through hole. [Figure 12] 5 is an enlarged view of a part of FIG. 4, showing an example of the optical paths of a first light beam emitted from a first light source and a second light beam emitted from a second light source. [Figure 13] FIG. 4 is a diagram showing a low beam light distribution pattern in this embodiment. [Figure 14] FIG. 4 is a diagram showing a high beam light distribution pattern in this embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0024] Preferred embodiments of a vehicle lamp according to the present invention will now be described in detail with reference to the drawings. The embodiments exemplified below are intended to facilitate understanding of the present invention and are not intended to limit the present invention. The present invention can be modified and improved within the scope of the claims without departing from the spirit thereof. The present invention may also be implemented by appropriately combining the components in the embodiments exemplified below. Note that in the drawings referred to below, the dimensions of each component may be changed to facilitate understanding. Also, in the drawings, for ease of viewing, similar components may be denoted with reference numerals only in some cases, and some reference numerals may be omitted.

[0025] FIG. 1 is a side view showing a vehicle lamp according to this embodiment. The vehicle lamp according to this embodiment is a vehicle headlamp. Vehicle headlamp is generally provided on each of the left and right sides in front of the vehicle. In this specification, "right" means the right side in the forward direction of the vehicle, and "left" means the left side in the forward direction of the vehicle. The left and right vehicle headlamp have the same configuration except that their shapes are roughly symmetrical in the left-right direction. Therefore, the following description will focus on one of the vehicle headlamp.

[0026] The vehicle headlamp 1 of this embodiment mainly comprises a housing 10 and a lamp unit LU. In Fig. 1, the housing 10 is shown in vertical cross section. The housing 10 has a lamp housing 11 and a light-transmitting front cover 12. The front of the lamp housing 11 is open, and the front cover 12 is fixed to the lamp housing 11 so as to close the opening. The space formed by the lamp housing 11 and the front cover 12 is a lamp chamber R, and the lamp unit LU is housed in this lamp chamber R.

[0027] Fig. 2 is an exploded perspective view of the lamp unit LU, as viewed from diagonally above the front. Fig. 3 is a front view of the lamp unit LU, as viewed from the front. Fig. 4 is a cross-sectional view of the lamp unit LU taken along line IV-IV in Fig. 3. As shown in Figs. 1 to 4, the lamp unit LU of this embodiment mainly comprises a heat sink 20, a light source section 30, a projection lens 35, a light guide 40, a beam shaper 50, a reinforcing member 60, and a holder 80.

[0028] 1 and 2, the heat sink 20 of this embodiment has a metal base plate 21 that extends generally vertically and in the left-right direction, and a plurality of heat dissipation fins 22 are provided integrally with the base plate 21 on the rear and front sides of the base plate 21. Three bosses 23 that protrude forward are provided integrally with the base plate 21 on the front side of the base plate 21. A screw hole 24 is provided in each boss 23 from the tip surface along the boss 23.

[0029] The light source unit 30 of this embodiment includes three first light sources 31a, 31b, and 31c, a second light source 32, and a circuit board 33. The circuit board 33 is placed on the front surface of the base plate 21 of the heat sink 20 and fixed to the base plate 21 with screws (not shown). The first light sources 31a, 31b, and 31c and the second light source 32 are mounted on the circuit board 33 and emit white light forward when power is supplied from the circuit board 33. In this embodiment, the first light sources 31a, 31b, and 31c and the second light source 32 are light-emitting diodes (LEDs). The first light source 31a is disposed to the right of the first light source 31b with a gap therebetween, and the first light source 31c is disposed to the left of the first light source 31b with a gap therebetween, and these first light sources 31a, 31b, and 31c are aligned in the left-right direction. The first light sources 31a, 31b, and 31c are light sources for low beam and emit a first light forward that forms a low beam light distribution pattern. The second light source 32 is disposed below the first light sources 31a, 31b, and 31c, and the second light source 32 and the first light source 31b are aligned in a generally vertical direction. The second light source 32 is a light source for high beam and emits a second light forward that forms a high beam light distribution pattern together with the first light. The types and numbers of the first light sources 31a, 31b, and 31c and the second light sources 32 are not particularly limited.

[0030] The projection lens 35 is a lens that changes the divergence angle of light that passes through it, and is disposed forward of the first light sources 31a, 31b, 31c and the second light source 32. In this embodiment, the projection lens 35 is a biconvex aspherical lens with a generally oval track shape that is elongated in the left-right direction. As shown in FIG. 4, the optical axis 35C of the projection lens 35 extends in the front-rear direction and passes between the first light source 31b and the second light source 32. Note that FIG. 4 is a vertical cross-sectional view of the lighting unit LU taken along the optical axis 35C. A flange portion 36 that protrudes outward and extends around the entire periphery is provided on the outer peripheral surface of the projection lens 35. Examples of materials that can be used to form the projection lens 35 include resin and glass.

[0031] 5 is a cross-sectional view of the lamp unit LU taken along line VV in FIG. 3, and is a horizontal cross-sectional view of the lamp unit LU passing through the first light sources 31a, 31b, and 31c. Note that the heat sink 20 is omitted from FIG. 5. As shown in FIGS. 2, 4, and 5, the light guide 40 is disposed between the first light sources 31a, 31b, and 31c and the second light source 32 and the projection lens 35, and guides the first light emitted from the first light sources 31a, 31b, and 31c and the second light emitted from the second light source 32 to enter the projection lens 35.

[0032] The light guide 40 of this embodiment has three first incident surfaces 41a, 41b, and 41c and a second incident surface 42 on the rear side, and an exit surface 43 on the front side. The first light from the first light source 31a is incident on the first incident surface 41a, the first light from the first light source 31b is incident on the first incident surface 41b, the first light from the first light source 31c is incident on the first incident surface 41c, and the second light from the second light source 32 is incident on the second incident surface 42. In addition, the light guide 40 is provided with plate-shaped flanges 48 on the top and both left and right sides at its front end, which protrude outward and extend along the outer edge of the front end of the light guide 40.

[0033] The light guide 40 guides the first light incident through the first incident surfaces 41a, 41b, and 41c to the exit surface 43 either directly or by total reflection, and guides the second light incident through the second incident surface 42 to the exit surface 43 either directly or by total reflection. The exit surface 43 emits the guided first light and second light toward the projection lens 35. In this embodiment, the exit surface 43 is curved concavely toward the rear. As shown in FIG. 4 , a beam shaper 50 (described later) is disposed between the exit surface 43 and the projection lens 35. The region of the exit surface 43 above the rear end of the beam shaper 50 is a first exit region 43a from which the first light is emitted. The region below the rear end of the beam shaper 50 is a second exit region 43b from which the second light is emitted. The light guide 40 guides the first light and the second light in this manner. Therefore, the first light sources 31a, 31b, and 31c and the light guide 40 form a first light-emitting optical system LE1 that emits a first light forward. The second light source 32 and the light guide 40 form a second light-emitting optical system LE2 that emits a second light forward, and the first light-emitting optical system LE1 and the second light-emitting optical system LE2 share the light guide 40. The first portion of the first light-emitting optical system LE1 that emits the first light is a first emission region 43a on the emission surface 43. The second portion of the second light-emitting optical system LE2 that emits the second light is a second emission region 43b on the emission surface 43, and the second emission region 43b is located below the first emission region 43a, which is the first portion. The optical axis LE1C of the light emitted from the first light-emitting optical system LE1 tilts downward toward the front, and the optical axis LE2C of the light emitted from the second light-emitting optical system LE2 tilts upward toward the front.

[0034] Fig. 6 is a perspective view showing the beam shaper 50 and the reinforcing member 60, as viewed from diagonally above the front. Fig. 7 is a plan view showing the beam shaper 50, as viewed from above. Note that the upper side in Fig. 7 is the front side of the vehicle, and the lower side is the rear side of the vehicle. As will be described in detail later, a reinforcing member 60 is superimposed on the beam shaper 50.

[0035] As shown in FIGS. 6 and 7 , the beam shaper 50 of this embodiment is a flat, plate-like member extending in the front-rear and left-right directions, and is elongated in the left-right direction. The leading edge of the beam shaper 50 includes a central leading edge CE1 and a pair of outer leading edges OE1 connected to both left-right ends of the central leading edge CE1. Therefore, the front end portion of the beam shaper 50 includes a central leading edge 51 including the entire central leading edge CE1, and a pair of outer leading edges 52 connected to both left-right ends of the central leading edge 51, each including the entire outer leading edge OE1. In this embodiment, the central leading edge CE1 is curved in an arc that is concave toward the rear, and the pair of outer leading edges OE1 are located on the same line extending in the left-right direction. Therefore, the central leading edge 51 is curved in an arc that is concave toward the rear, and the pair of outer leading edges 52 are located on the same line extending in the left-right direction. For ease of understanding, in FIG. 7, the central front end 51 is hatched with dots, and the outer front end 52 is hatched with oblique lines.

[0036] The trailing edge of the beam shaper 50 includes a central trailing edge CE2 and a pair of outer trailing edges OE2 connected to both ends of the central trailing edge CE2 in the left-right direction. In this embodiment, the central trailing edge CE2 is curved in an arc shape that is concave rearward, and the pair of outer trailing edges OE2 are located on the same straight line extending in the left-right direction. In addition, both ends of the central trailing edge CE2 are located outward in the left-right direction from both ends of the central leading edge CE1.

[0037] In this embodiment, a slit 53 is formed in each of the outer front end portions 52 on both the left and right sides, and the slit 53 extends beyond the outer front end portion 52 and rearward from the outer front end portion 52. The slit 53 is V-shaped, and a center line 53L of the slit 53 in the width direction is inclined rearward away from the central front end portion 51. The right and left slits 53 have generally symmetrical shapes. The rear end 53p of the slit 53 is located forward of the rearmost portion 51p of the central front end portion 51. The edge of the right slit 53 is connected to the right end CE1a of the central front edge CE1, and the edge of the left slit 53 is connected to the left end CE1b of the central front edge CE1. In other words, the slit 53 is interposed between the central front end portion 51 and the outer front end portion 52.

[0038] The shape of the slits 53 is not limited, and may be, for example, rectangular or U-shaped, and the right and left slits 53 may have different shapes or sizes. The center line 53L may be parallel to the front-to-rear direction or may incline rearward toward the central front end portion 51. The edge of the right slit 53 may not be connected to the right end CE1a of the central leading edge CE1, and the edge of the left slit 53 may not be connected to the left end CE1b of the central leading edge CE1.

[0039] The upper surface 50S1 of the beam shaper 50 of this embodiment has a first step portion 55a and a second step portion 55b. These step portions 55a and 55b are formed by bending the beam shaper 50. The area of ​​the upper surface 50S1 other than these step portions 55a and 55b is a surface that extends generally horizontally.

[0040] The first step portion 55a in this embodiment extends linearly in the front-to-rear direction. The front end of the first step portion 55a connects to the rearmost portion of the central leading edge CE1, and the rear end of the first step portion 55a connects to the rearmost portion of the central trailing edge CE2. The height of the first step portion 55a is constant in the extension direction of the first step portion 55a, but it does not have to be constant. Furthermore, the first step portion 55a may extend in a direction non-parallel to the front-to-rear direction.

[0041] In this embodiment, the second step portion 55b is located to the right of the right slit 53 and extends linearly in the front-to-rear direction. The front end of the second step portion 55b connects to the right outer leading edge OE1, and the rear end of the second step portion 55b connects to the center trailing edge CE2. The height of the second step portion 55b is generally constant in the extension direction of the second step portion 55b.

[0042] In this embodiment, the first step portion 55a is formed by an inclined surface that slopes upward from left to right, and the second step portion 55b is formed by a surface that extends substantially vertically. The region between the first step portion 55a and the second step portion 55b on the upper surface 50S1 is higher than the other regions.

[0043] The height of the first step portion 55a is the same as the height of the second step portion 55b, and the height of the region to the left of the first step portion 55a is the same as the height of the region to the right of the second step portion 55b, but these heights may be different from each other. The first step portion 55a may be formed by a surface that extends in a substantially vertical direction, and the second step portion 55b may be formed by an inclined surface that is inclined with respect to the vertical direction.

[0044] A through-hole 50h1 penetrating in the thickness direction and two fitting through-holes 50h3 are provided in a region of the beam shaper 50 to the right of the right end CE1a of the central leading edge CE1 and to the left of the left end CE1b of the central leading edge CE1. That is, the through-hole 50h1 and the two fitting through-holes 50h3 are provided in a region to the right of the right end of the central front end 51 and a region to the left of the left end of the central front end 51, respectively. In this embodiment, the through-hole 50h1 and the fitting through-hole 50h3 are provided in a region of the beam shaper 50 to the right of the second step portion 55b and a region to the left of the left slit 53, respectively. In addition, in this embodiment, another fitting through-hole 50h4 is provided on the rear side between the left slit 53 and the first step portion 55a. As described above, the height of the region to the left of the first step portion 55a is the same as the height of the region to the right of the second step portion 55b. Therefore, the through hole 50h1 and the fitting through holes 50h3 and 50h4 are provided at the same height. The left through hole 50h1 is generally circular, and the right through hole 50h1 is generally oval-shaped and elongated in the left-right direction. The fitting through holes 50h3 and 50h4 are also generally circular. In this embodiment, a fitting through hole 50h3 is also provided on the rear side between the left slit 53 and the first step portion 55a.

[0045] In this embodiment, a protrusion 56 is provided on the upper surface 50S1 of the beam shaper 50, and is located between the first step portion 55a and the second step portion 55b. The protrusion 56 has a hemispherical shape that protrudes upward, and is formed by curving the beam shaper 50. The position of the protrusion 56 is not limited, and the protrusion 56 does not necessarily have to be provided on the upper surface 50S1.

[0046] Examples of materials that form the beam shaper 50 include metal plates and plated metal plates, and examples of metals include stainless steel and carbon steel. The thickness of the beam shaper 50 is, for example, 0.05 mm to 1.0 mm. As will be described later, the beam shaper 50 is a reflective member that reflects light from the first light sources 31a, 31b, and 31c and the second light source 32.

[0047] As described above, the reinforcing member 60 is superimposed on the beam shaper 50. Fig. 8 is a front view showing the state in which the reinforcing member 60 is superimposed on the beam shaper 50, and is a front view of the beam shaper 50 and the reinforcing member 60 as seen from the front.

[0048] 6 to 8, the reinforcing member 60 of this embodiment is a plate-like member extending in the front-rear and left-right directions. The reinforcing member 60 is composed of a pair of left and right mounting portions 62 and a connecting portion 63, and the shape of the reinforcing member 60 is generally the same as that of the beam shaper 50 except for the front edge. An upper surface 60S1 of the reinforcing member 60 faces a lower surface 50S2 of the beam shaper 50, and the reinforcing member 60 is superimposed on the beam shaper 50 from below. In FIG. 7, the reinforcing member 60 is indicated by a two-dot chain line, and the position of the reinforcing member 60 is slightly shifted.

[0049] The right mounting portion 62 overlaps only with a portion of the beam shaper 50 to the right of the right end CE1a of the central leading edge CE1, and in this embodiment, overlaps only with a portion to the right of the first step portion 55a. The left mounting portion 62 overlaps only with a portion of the beam shaper 50 to the left of the left end CE1b, and in this embodiment, overlaps only with a portion to the left of the left slit 53. Each mounting portion 62 is provided with a through hole 60h1 that overlaps with the through hole 50h1 of the beam shaper 50. Each mounting portion 62 also has a protrusion 62t provided at a position corresponding to the fitting through hole 50h3, and is fixed to the beam shaper 50 by press-fitting the protrusion 62t into the fitting through hole 50h3.

[0050] The method for fixing the reinforcing member 60 to the beam shaper 50 is not limited, and the reinforcing member 60 may be fixed by laser welding, for example. The position of the part where the reinforcing member 60 is fixed to the beam shaper 50 is not particularly limited.

[0051] The connecting portion 63 extends from one mounting portion 62 to the other mounting portion 62, and at least a portion of the connecting portion 63 overlaps with the beam shaper 50. In this embodiment, the right end of the connecting portion 63 connects to the left rear portion of the right mounting portion 62, and the left end of the connecting portion 63 connects to the right rear portion of the left mounting portion 62. The connecting portion 63 has a protrusion 63t provided at a position corresponding to the fitting through hole 50h4, and is fixed to the beam shaper 50 by press-fitting the protrusion 63t into the fitting through hole 50h4. The connecting portion 63 runs along a portion of the beam shaper 50 to the left of the first step portion 55a, and a gap GP is formed between the connecting portion 63 and a portion of the beam shaper 50 between the first step portion 55a and the second step portion 55b.

[0052] 7, in a plan view, the central front edge CE1 of the beam shaper 50 is located forward of the connection portion 63. The beam shaper 50 includes a portion that includes the central front end portion 51 and does not overlap with the reinforcing member 60, and a portion that overlaps with the reinforcing member 60 and to which the reinforcing member 60 is fixed. In this embodiment, the front edge 63E of the connection portion 63 is curved in an arc that is concave rearward, and the distance between the front edge 63E and the central front edge CE1 is maintained at a predetermined distance or more in the left-right direction.

[0053] In addition, in this embodiment, the reinforcing member 60 does not overlap the slit 53 of the beam shaper 50 in plan view.

[0054] The reinforcing member 60 may be formed of the same material as the beam shaper 50, and the thickness of the reinforcing member 60 is, for example, 0.05 mm to 1.0 mm. In this embodiment, the reinforcing member 60 is thicker than the beam shaper 50, but the thickness of the reinforcing member 60 may be equal to or less than the thickness of the beam shaper 50. In this embodiment, the Young's modulus of the reinforcing member 60 is higher than that of the beam shaper 50, but the Young's modulus of the reinforcing member 60 may be equal to or less than that of the beam shaper 50.

[0055] 4, the beam shaper 50 to which the reinforcing member 60 is fixed in this manner is disposed between the projection lens 35 and a first emission region 43a of the emission surface 43, which is a portion of the light guide 40 that emits the first light, and a second emission region 43b of the emission surface 43, which is a portion of the light guide 40 that emits the second light. In this embodiment, the beam shaper 50 crosses the emission surface 43 when viewed from the front along the optical axis 35C of the projection lens 35. Furthermore, the optical axis 35C of the projection lens 35 passes through or near the first step portion 55a of the beam shaper 50, and the rear focal point of the projection lens 35 is located at or near the central front edge CE1 of the beam shaper 50.

[0056] 2, 4, and 5, the holder 80 of this embodiment has a support portion 81 and a protective portion 82, and supports the projection lens 35, the light guide 40, and the beam shaper 50. The holder 80 may be made of a material such as a resin, such as opaque polycarbonate, and in this embodiment, the support portion 81 and the protective portion 82 are integrally formed.

[0057] The support portion 81 is a cylindrical member extending in the front-rear direction, and has a flange portion 83 protruding from the inner circumferential surface at its front end. The flange portion 36 of the projection lens 35 abuts against this flange portion 83 from the front side, and the flange portion 36 is fixed to the flange portion 83 by, for example, ultrasonic welding or laser welding. A predetermined range extending downward from the rear end of the support portion 81 toward the front is cut out, and a support plate 84 extending generally horizontally outward is provided at the lower right and left ends of this predetermined range. Furthermore, a connecting wall 87 protruding from the outer surface in a direction generally perpendicular to the extension direction of the support portion 81 is provided at the rear end of the support portion 81. As shown in FIG. 3 , a pedestal portion 85 protruding downward is provided on the underside of the support plate 84. A portion of the beam shaper 50 outside the central front edge CE1 abuts against the tip of the pedestal portion 85 from below, and is fixed to the pedestal portion 85 together with the mounting portion 62 of the reinforcing member 60.

[0058] In this embodiment, the boss 90 inserted into the through hole 50h1 of the beam shaper 50 and the through hole 60h1 of the reinforcing member 60 is heat-stakingly performed. FIG. 9 is a cross-sectional view taken along line AA in FIG. 7, showing the boss 90 inserted into the left-side through hole 50h1. As shown in FIG. 9, in a holder 80 serving as a base, the boss 90 is provided on a pedestal portion 85 of a support plate 84 serving as a support portion that supports the beam shaper 50. As indicated by the dotted line in FIG. 9, the boss 90 extends downward from the pedestal portion 85 and is inserted, in this order, into the left-side through hole 50h1 of the beam shaper 50 and the left-side through hole 60h1 of the reinforcing member 60. Then, by heating the tip of the boss 90, a head portion 86, indicated by a solid line, is formed on the side of the left-side through hole 60h1 of the reinforcing member 60 opposite the beam shaper 50. In this way, the beam shaper 50 and the reinforcing member 60 are sandwiched between the base portion 85 and the head portion 86. Here, the head portion 86 may press the reinforcing member 60 or may simply be in contact with it.

[0059] The boss 90 and the base portion 85 constitute a fixing portion 95 that fixes the beam shaper 50 and the reinforcing member 60. In Fig. 7, the portion 50a that is pressed against the head portion 86 by heat caulking is indicated by a dashed line.

[0060] The method for fixing the beam shaper 50 in the left through-hole 50h1 is not particularly limited. For example, the beam shaper 50 may be fixed with a screw or by laser welding, in which case the left through-hole 50h1 may not be formed.

[0061] FIG. 10 is a cross-sectional view taken along line BB in FIG. 7 , showing the boss 90 inserted into the right-side through-hole 50h1. As shown in FIG. 10 , in a holder 80 serving as a base, the boss 90 is provided on a pedestal 85 of a support plate 84 serving as a support portion supporting the beam shaper 50. As indicated by the dotted line in FIG. 10 , the boss 90 extends downward from the pedestal 85 and is inserted, in this order, through the right-side through-hole 50h1 of the beam shaper 50, the right-side through-hole 60h1 of the reinforcing member 60, and a washer 91. Then, by heating the tip of the boss 90, a head portion 86, indicated by a solid line, is formed on the opposite side of the beam shaper 50 from the right-side through-hole 60h1 of the reinforcing member 60. Note that in FIG. 7 , a portion 50b pressed against the head portion 86 via the washer 91 by heat staking is indicated by a dashed line. The head 86 does not have to press the washer 91, but may simply be in contact with it, and a gap may be formed between the base 85 and the beam shaper 50.

[0062] The right through-hole 50h1 is an elongated hole whose diameter in the direction from the part 50a fixed to the fixing part 95 toward the right through-hole 50h1 is longer than the diameter in the direction perpendicular to that direction.

[0063] 11 is a diagram showing the positional relationship between the washer 91 and the right-side through-hole 50h1. In this embodiment, a portion of an inner periphery 91i of the washer 91 overlaps the through-hole 50h1, and a portion of an outer periphery 91o of the washer 91 is located outside the through-hole 50h1. The washer 91 is made of fluororesin.

[0064] In this embodiment, the glass transition point of the resin that constitutes the boss 90 is lower than the glass transition point of the resin that constitutes the washer 91. This makes it possible to make the washer 91 less likely to melt when the boss 90 is heated for thermal caulking.

[0065] In this embodiment, the washer 91 is fused to the boss 90 .

[0066] Next, the protection section 82 will be described.

[0067] 2, 4, and 5, the protective portion 82 is a plate-like member located behind the support portion 81 and surrounding both left and right sides and the top of the light guide 40. In this embodiment, the protective portion 82 surrounds both left and right sides and the top of the front portion of the light guide 40. The front end of the protective portion 82 is connected to the connecting wall 87, and the flange portion 48 of the light guide 40 abuts against the connecting wall 87 from the rear side, and the flange portion 48 is fixed to the connecting wall 87 by, for example, ultrasonic welding or laser welding. In this manner, the projection lens 35, the light guide 40, and the beam shaper 50 are supported by the holder 80.

[0068] 2 to 4, the rear end of the protective part 82 is provided with three fixing plates 88 that protrude generally vertically from the outer surface. The fixing plates 88 correspond to the bosses 23 of the heat sink 20, and each fixing plate 88 has a through hole 88h. The fixing plates 88 abut against the tips of the bosses 23 from the front side, and screws 89 are inserted into the through holes 88h and fastened to the screw holes 24, thereby fixing the holder 80 to the heat sink 20. In this way, the projection lens 35, the light guide 40, and the beam shaper 50 are fixed to the heat sink 20 via the holder 80.

[0069] Next, we will explain how a low-beam light distribution pattern is formed by the vehicle headlamp 1. Fig. 12 is an enlarged view of a portion of Fig. 4, showing an example of the optical paths of the first light emitted from the first light source and the second light emitted from the second light source. Note that the reflection angles and refraction angles of the light shown in Fig. 12 may not be accurate.

[0070] To form a low-beam light distribution pattern, first light L1 is emitted from the first light-emitting optical system LE1. Specifically, the first light L1 is emitted from the first light sources 31a, 31b, and 31c. The first light L1 from the first light source 31b enters the light guide 40 from the first incident surface 41b and is emitted from the first emission region 43a toward the projection lens 35 located in front. The same applies to the first light L1 from the first light sources 31a and 31c. Most of the first light L1 emitted from the first emission region 43a passes above the beam shaper 50 and directly enters the projection lens 35. A portion of the first light L1 emitted from the first emission region 43a is irradiated onto the upper surface 50S1 of the beam shaper 50. The region of the upper surface 50S1 irradiated with the first light L1 is in contact with the entire central front edge CE1 of the beam shaper 50, and this region includes the upper surface of the central front end 51 of the beam shaper 50. The upper surface of the central front end 51 of the beam shaper 50, part of the upper surface 50S1 of the beam shaper 50, reflects a portion of the first light L1 toward the projection lens 35. Therefore, a cutoff line is formed in the light distribution pattern formed by the first light L1 by the central front end 51, and this light distribution pattern becomes a low beam light distribution pattern. In other words, the central front end 51 forms a cutoff line of the low beam light distribution pattern, and the cutoff line of the low beam light distribution pattern has a shape corresponding to the central front end 51. In this embodiment, a protrusion 56 is located within the region of the upper surface 50S1 irradiated with the first light L1. The protrusion 56 reflects and blocks another portion of the first light L1 so that it does not enter the projection lens 35. This allows a predetermined area in the low-beam light distribution pattern to be darkened. Furthermore, since the area on the upper surface 50S1 irradiated with the first light L1 is in contact with the entire central leading edge CE1 as described above, the first light L1 also irradiates the area on the upper surface 50S1 between the central leading edge CE1 and the protrusion 56, brightening that area. This allows a gap to be formed between the predetermined darkened area and the cutoff line. In this way, the low-beam light distribution pattern is formed by the first light L1, and light having this low-beam light distribution pattern passes through the projection lens 35 and is emitted from the vehicle headlamp 1 via the front cover 12.

[0071] 7, the beam shaper 50 includes a reflecting portion 97 that reflects light from the light source unit 30 so that a cutoff line CL of the low beam is formed between the portion 50a fixed to the fixing portion 95 around the left through-hole 50h1 and the right through-hole 50h1, and a pair of connecting portions 99 that are connected to the portion 50a side and the right through-hole 50h1 side of the reflecting portion 97, respectively. A slit 53 is formed in each of the pair of connecting portions 99.

[0072] FIG. 13 is a diagram showing a low-beam light distribution pattern according to this embodiment. In FIG. 13, S denotes the horizontal line, V denotes a vertical line passing through the center of the vehicle in the lateral direction, and the low-beam light distribution pattern PL projected on a virtual vertical screen located 25 m ahead of the vehicle is shown by a thick line. The light guide 40 and the beam shaper 50 are shaped so that the light distribution pattern of the first light L1 incident on the projection lens 35 becomes the low-beam light distribution pattern PL. The low-beam light distribution pattern PL of this embodiment is suitable for countries and regions where vehicles drive on the right side of the road. The cutoff line CL of the low-beam light distribution pattern PL corresponds to the shape of the central front end 51 of the beam shaper 50, and the cutoff line CL includes a step portion CLa corresponding to the first step portion 55a. The step portion CLa is a line sloping upward toward the right from an elbow point EP located below the horizontal line S and on or near the vertical line V. The portions of the cutoff line CL to the right and left of the step portion CLa extend horizontally. In this embodiment, the portion of the cutoff line CL to the right of the step portion CLa is lower than the portion to the left of the step portion CLa. Furthermore, the region AR1 in the low beam light distribution pattern PL is darker than the surrounding area. This region AR1 is located closer to the oncoming lane OL than the elbow point EP. Therefore, the region AR1 may overlap with the road surface between the vehicle and an oncoming vehicle, thereby reducing glare from light reflected from the road surface to the driver of the oncoming vehicle. The position and shape of the region AR1 can be changed by adjusting the position and shape of the protrusion 56. Furthermore, the absence of the protrusion 56 on the upper surface 50S1 prevents the region AR1 from being darkened.

[0073] Next, the formation of a high beam light distribution pattern by the vehicle headlamp 1 will be described.

[0074] To form a high-beam light distribution pattern, the first light L1 is emitted from the first light-emitting optical system LE1, and the second light L2 is emitted from the second light-emitting optical system LE2. Specifically, the first light L1 is emitted from the first light sources 31a, 31b, and 31c, and the second light L2 is emitted from the second light source 32. Therefore, as described above, the low-beam light distribution pattern PL is formed by the first light L1, and light having the low-beam light distribution pattern PL is emitted from the vehicle headlamp 1. As shown in FIG. 12 , the second light L2 emitted from the second light source 32 enters the light guide 40 from the second incident surface 42. The second light L2 that enters the light guide 40 is emitted from the second emission region 43b toward the projection lens 35 located forward. Most of the second light L2 emitted from the second emission region 43b passes below the beam shaper 50 and directly enters the projection lens 35, which is located in front of the second emission region 43b. A portion of the second light L2 emitted from the second emission region 43b is irradiated onto a portion of the lower surface 50S2 of the beam shaper 50 that is exposed to the outside, the lower surface 60S2 of the reinforcing member 60, and portions of the side surfaces of the reinforcing member 60. The portion of the lower surface 50S2 that is exposed to the outside reflects a portion of this second light L2 toward the projection lens 35. The region of the lower surface 50S2 that is irradiated with the second light L2 is in contact with the entire central front edge CE1 of the beam shaper 50, and this region includes the lower surface of the central front end 51 of the beam shaper 50. The lower surface of the central front end 51 of the lower surface 50S2 reflects a portion of the second light L2 toward the projection lens 35. Therefore, a cutoff line is formed in the light distribution pattern formed by the second light L2 by the central front end portion 51, and this light distribution pattern becomes an additional light distribution pattern. The cutoff line of the additional light distribution pattern has a shape corresponding to the central front end portion 51, and this additional light distribution pattern is added to the low beam light distribution pattern PL, forming a high beam light distribution pattern. Therefore, the second light L2 is light that forms the high beam light distribution pattern together with the first light L1. Light having this additional light distribution pattern passes through the projection lens 35 and is emitted from the vehicle headlamp 1 via the front cover 12. As described above, the cutoff line of the additional light distribution pattern is formed by the central front end portion 51, similar to the cutoff line CL of the low beam light distribution pattern PL.Therefore, the cutoff line of the additional light distribution pattern and the cutoff line CL of the low-beam light distribution pattern PL generally coincide with each other, and the high-beam light distribution pattern is formed by connecting the additional light distribution pattern and the low-beam light distribution pattern PL. In this embodiment, the high-beam light distribution pattern is formed by superimposing the first light L1 and the second light L2. However, the first light L1 and the second light L2 do not have to overlap. In this case, by making the gap between the cutoff line of the additional light distribution pattern and the cutoff line CL of the low-beam light distribution pattern PL invisible to the human eye on a virtual screen, for example, 25 meters away, the additional light distribution pattern and the low-beam light distribution pattern PL can be made to appear connected.

[0075] Fig. 14 is a diagram showing a high beam light distribution pattern in this embodiment, and is a diagram showing the high beam light distribution pattern in the same way as Fig. 13. In Fig. 14, the cutoff line CL in the low beam light distribution pattern PL is shown by a dotted line. The area below the cutoff line CL in the high beam light distribution pattern PH is formed by the first light L1, and the area above the cutoff line CL is formed by the second light L2.

[0076] As described above, the vehicle headlamp 1 of this embodiment includes the light source unit 30, the beam shaper 50 as a reflective member that reflects light from the light source unit 30 and has a through hole 50h1 formed therein, the base unit 85 as a support unit that supports the beam shaper 50, and the holder 80 as a base having a boss 90 that extends from the base unit 85 toward the beam shaper 50 and is inserted into the through hole 50h1. The vehicle headlamp 1 also includes a washer 91 that is located on the opposite side of the beam shaper 50 from the base unit 85 and is inserted into the boss 90, and a fixing portion 95 to which a portion of the beam shaper 50 separated from the through hole 50h1 is fixed, and a portion of the boss 90 on the opposite side of the washer 91 from the beam shaper 50 side is heat caulked. The beam shaper 50 forms a cutoff line CL in the low beam light distribution pattern PL.

[0077] According to the vehicle headlamp 1 of this embodiment, the resin at the portion where the boss 90 is heat-stakingly fixed can be blocked by the washer 91, compared to when the washer 91 is not provided. This can prevent the resin in the through-hole 50h1 from adhering to the beam shaper 50, and can facilitate the movement of the position of the through-hole 50h1 relative to the boss 90. Therefore, when the beam shaper 50 thermally expands due to light from the light source unit 30, the position of the through-hole 50h1 can shift relative to the boss 90, preventing the beam shaper 50 from bending and suppressing the influence of heat on the low beam light distribution pattern PL.

[0078] Furthermore, in the vehicle headlamp 1 of this embodiment, a portion of the inner periphery 91i of the washer 91 overlaps the through hole 50h1. Therefore, according to the vehicle headlamp 1 of this embodiment, compared to a case in which the inner periphery 91i of the washer 91 does not overlap the through hole 50h1, the resin at the portion where the boss 90 is heat-stakingly fastened can be more easily blocked by the washer 91, and adhesion between the resin in the through hole 50h1 and the beam shaper 50 can be more effectively suppressed. From this perspective, it is sufficient that a portion of the inner periphery 91i of the washer 91 overlaps the through hole 50h1 and at least a portion of the outer periphery 91o of the washer 91 is located outside the through hole 50h1. For example, the entire inner periphery 91i may overlap the through hole 50h1. However, the inner periphery 91i of the washer 91 does not have to overlap the through hole 50h1.

[0079] Furthermore, in the vehicle headlamp 1 of this embodiment, the washer 91 is made of fluororesin. Therefore, according to the vehicle headlamp 1 of this embodiment, the coefficient of friction between the washer 91 and the beam shaper 50 can be reduced. This makes it easier for the beam shaper 50 to shift when thermally expanding due to light from the light source unit 30, and can further prevent the beam shaper 50 from bending. Note that the washer 91 may be made of a resin other than fluororesin. The washer 91 may also be made of a material other than resin, such as metal. However, it is preferable that the washer 91 be made of resin.

[0080] In the vehicle headlamp 1 according to this embodiment, the glass transition point of the resin that constitutes the boss 90 is lower than the glass transition point of the resin that constitutes the washer 91. Therefore, according to the vehicle headlamp 1 according to this embodiment, when the heat-caulked portion of the boss 90 melts, the washer 91 can be made less likely to melt. Note that the glass transition point of the resin that constitutes the boss 90 does not have to be lower than the glass transition point of the resin that constitutes the washer 91.

[0081] In the vehicle headlamp 1 of this embodiment, the washer 91 is fused to the boss 90. Therefore, according to the vehicle headlamp 1 of this embodiment, rattle of the washer 91 can be made less likely to occur and abnormal noise can be suppressed compared to when the washer 91 is not fused to the boss 90. Note that the washer 91 may not be fused to the boss 90.

[0082] In the vehicle headlamp 1 of this embodiment, the through hole 50h1 is an elongated hole whose diameter in a direction from the portion 50a fixed to the fixing portion 95 toward the through hole 50h1 is longer than its diameter in a direction perpendicular to that direction. Therefore, according to the vehicle headlamp 1 of this embodiment, compared to a case in which the through hole 50h1 is a round hole, positional deviation in a direction perpendicular to the direction from the portion 50a fixed to the fixing portion 95 of the beam shaper 50 toward the boss 90 is suppressed, and the beam shaper 50 may be displaced when thermally expanded by light from the light source unit 30. This can suppress bending of the beam shaper 50 and suppress the influence of heat on the low beam light distribution pattern PL. Note that the longitudinal direction of the elongated through hole 50h1 may be a direction different from the direction from the portion 50a toward the through hole 50h1. Furthermore, the through hole 50h1 does not have to be an elongated hole.

[0083] In the vehicle headlamp 1 according to this embodiment, the beam shaper 50 includes a reflector 97 between the portion 50a fixed by the fixing portion 95 and the through-hole 50h1, and a pair of connecting portions 99 connected to the portion 50a side of the reflector 97 and the right-side through-hole 50h1, respectively. The reflector 97 reflects light from the light source unit 30 so as to form a low beam cutoff line CL, and a slit 53 is formed in each of the pair of connecting portions 99. Therefore, according to the vehicle headlamp 1 according to this embodiment, when the beam shaper 50 thermally expands due to the light from the light source unit 30, the slit 53 deforms to absorb the deformation caused by the expansion, thereby further suppressing bending of the beam shaper 50. From this perspective, it is sufficient that the slit 53 is formed in at least one of the pair of connecting portions 99. However, the beam shaper 50 does not necessarily have to be formed with the slit 53.

[0084] Although the present invention has been described above using the above-mentioned embodiments as examples, the present invention is not limited to these.

[0085] For example, in the above embodiment, the reinforcing member 60 is superimposed on the beam shaper 50 from below, but the reinforcing member 60 may be superimposed on the beam shaper 50 from above.

[0086] In the above embodiment, the vehicle headlamp 1 including the reinforcing member 60 has been described as an example. However, the vehicle headlamp 1 does not necessarily have to include the reinforcing member 60.

[0087] In the above embodiment, an example was shown in which the holder 80 that supports the projection lens 35 is the base. However, the base is not limited to this. Also, in the above embodiment, an example was shown in which the fixing portion 95 is included in the holder 80 as the base. However, the fixing portion 95 may be a member different from the base.

[0088] In the above embodiment, the beam shaper 50 that forms the cutoff line CL is described as an example of a reflective member that is attached by thermal caulking. However, the reflective member may be any member that reflects light from the light source unit 30. For example, the reflective member may be a reflector in a PES-type lamp that covers the light source from above. In this case, the base may be, for example, a heat sink on which the light source is disposed. Furthermore, the vehicular lamp that includes a reflective member does not have to be a vehicular headlamp, and the light emitted by the vehicular lamp may be light other than a low beam.

[0089] In the above embodiment, an example in which the washer 91 is not disposed on the left through-hole 50h1 side has been described, but this is not limiting. That is, the washer 91 may be disposed in the through-holes 50h1 on both the left and right sides, and the portion of the boss 90 opposite the beam shaper 50 side from the washer 91 may be heat-stakingly fastened.

[0090] In addition, a method for manufacturing a vehicle headlamp 1 as a vehicle lighting fixture, which includes a light source unit 30, a beam shaper 50 as a reflective member that reflects light from the light source unit 30 and has a through hole 50h1 formed therein, a base unit 85 as a support unit that supports the beam shaper 50, a holder 80 as a base having a boss 90 extending from the base unit 85, a washer 91, and a fixing unit 95 to which a portion of the beam shaper 50 spaced from the through hole 50h1 is fixed, includes the following steps. Specifically, the manufacturing method includes a first insertion step of inserting the boss 90 into the through hole 50h1 of the beam shaper 50, a second insertion step of inserting the boss 90 into the washer 91 after the first insertion step so that the washer 91 is positioned on the opposite side of the beam shaper 50 from the base portion 85, and a crimping step of heat crimping a portion of the boss 90 on the opposite side of the washer 91 from the beam shaper 50 after the second insertion step. With this configuration, when the boss 90 is melted by heat crimping, the molten resin can be blocked by the washer 91, making it possible to suppress adhesion between the resin and the beam shaper 50 within the through hole 50h1 and making it easier for the position of the through hole 50h1 to move relative to the boss 90. Therefore, in the manufactured vehicle headlamp 1, when the beam shaper 50 thermally expands due to light from the light source unit 30, the position of the through hole 50h1 may shift relative to the boss 90, preventing the beam shaper 50 from bending and suppressing the thermal effect on the low beam light distribution pattern PL. [Industrial Applicability]

[0091] According to the present invention, a vehicle lamp capable of suppressing the influence of heat on a light distribution pattern is provided, and can be used in fields such as vehicle headlights for automobiles and the like. [Explanation of symbols]

[0092] 1. Vehicle headlamp 30...Light source section 35 Projection lens 50···Beam Shaper 50h1...Through hole Top of the 50S1 beam shaper 51...Central front end 52...Outer front end 53 Slit 84...support plate 85···Base 90...Boss 91 Washer 95...Fixed part CL...Cutoff line L1: First light L2: Second light LE1: First light-emitting optical system LE2: Second light-emitting optical system PL···Low beam light distribution pattern PH High beam light distribution pattern

Claims

1. A light source unit; a reflecting member that reflects light from the light source unit and has a through hole formed therein; a base having a support portion that supports the reflecting member and a boss that extends from the support portion toward the reflecting member and is inserted into the through hole; a washer positioned on the opposite side of the support portion from the reflecting member and inserted into the boss; a fixing portion to which a portion of the reflecting member separated from the through hole is fixed; Equipped with The boss is heat-stakingly secured at a portion opposite to the reflecting member side relative to the washer. A vehicle lamp characterized by:

2. At least a portion of the inner periphery of the washer overlaps with the through hole.

2. A vehicle lamp according to claim 1.

3. The washer is made of resin.

2. A vehicle lamp according to claim 1.

4. The resin is a fluororesin.

4. A vehicle lamp according to claim 3.

5. The glass transition temperature of the resin constituting the boss is lower than the glass transition temperature of the resin constituting the washer.

4. A vehicle lamp according to claim 3.

6. The washer is fused to the boss.

4. A vehicle lamp according to claim 3.

7. The through hole is an elongated hole whose diameter in a direction from the part fixed to the fixing part toward the through hole is longer than the diameter in a direction perpendicular to the direction.

2. A vehicle lamp according to claim 1.

8. The reflecting member includes a reflecting portion that reflects light from the light source portion so that a cutoff line of a low beam is formed between a portion fixed by the fixing portion and the through hole, and a pair of connecting portions that are connected to the portion side and the through hole side of the reflecting portion, respectively, and a slit is formed in at least one of the pair of connecting portions.

2. A vehicle lamp according to claim 1.

Images